Composite removable hard top

ABSTRACT

A removable hardtop including inner and outer roof panels made of molded fiber reinforced sheet molding compound. An integral roll bar is formed in the inner roof panel. A hold down clamp and bracket having horizontal, vertical and transverse flanges mounted on a horizontal edge, vertical surface and transverse surface of a B pillar of a vehicle. A method of molding the inner and outer roof panels and assembling component parts to the inner and outer roof panels is also disclosed.

TECHNICAL FIELD

[0001] The present invention relates to a removable roof for a vehicleand a method of making a removable roof.

BACKGROUND ART

[0002] Removable roofs are known for use in conjunction with convertiblevehicles including premium vehicles such as the BMW 325 CI, BMW Z3, andas disclosed in U.S. Pat. No. 5,489,146 to Fischbach. Removable hardtops address one drawback of convertible vehicles by providing a durabletop for a vehicle during the winter months while the convertible top maybe kept in its stowed position protecting it against the elements.

[0003] Prior art removable hard tops are normally built on a framehaving multiple components to which rigid panels are assembled. In aneffort to improve rollover protection, metal roll bars may beincorporated into the removable roof structure or an active roll barsystem may be incorporated in other portions of the passengercompartment. Removable tops having a separate frame are expensive tomanufacture and are relatively heavy. As vehicles are normally assembledthere is a limited amount of twisting and tolerance stack up that canresult in variances in vehicle mounting locations that can complicatesecuring a removable roof to the vehicle.

[0004] Styling requirements may limit the space available for hold downclamps used to secure the sides of a removable top to a vehicle. Theinclusion of side windows in a removable top imposes substantiallimitations on the space available for hold down clamp assemblies. Whileit is desirable to provide larger, more robust hold down clampassemblies, space limitations and weight reduction considerationsprovide challenges in the design of removable vehicle roofs and theirassociated hold down clamp structures.

[0005] These and other problems and challenges are addressed byApplicant's invention as summarized below.

DISCLOSURE OF INVENTION

[0006] According to the present invention, a method of making aremovable roof for a vehicle is provided. The method includes forming anouter panel of the roof in a heated mold from a sheet of thermosetplastic resin having fiber reinforcement material distributed in theresin. The thermoset plastic resin sheet is formed in the mold to thenet size and shape of the roof outer panel. An inner panel of the roofis similarly formed in a second mold from a second sheet ofthermoplastic resin with fiber reinforcement material distributed in theresin. The second sheet is formed to the net size and shape of the roofinner panel. The inner and outer roof panels are both trimmed andassembled to appropriate mounting brackets and locking assemblies thatare assembled to the inner roof panel. The roof outer panel and roofinner panels are bonded together to form a removable roof for a vehicle.

[0007] One aspect of the invention is the formation of an integral rollbar on the roof inner panel as the roof inner panel is molded. Theintegral roll bar is designed to withstand a 5,000 pound load or one andone half times the unloaded vehicle weight, whichever is less.

[0008] According to another aspect of the invention, the inner and outerroof panels are formed from sheets of a sheet molding compound ofthermoset plastic resin that is reinforced with either glass fibers,carbon fibers, polyacrylonitrile or a combination thereof.

[0009] According to the invention, a removable roof for a vehicle isprovided for a vehicle having a windshield including a header on an Apillar located in front of the front vehicle doors and a B pillarlocated in front of and rearward of the front vehicle doors,respectively. The removable roof has a fiber reinforced thermoset resininner and outer panel. The inner panel preferably includes an integrallyformed roll bar. The removable roof for a vehicle is detachably securedto the vehicle by means of four attachment points two of which are rightand left hold down clamp assemblies that are secured to hold downbracket assemblies that are secured to the B pillar of the vehicle. Awindshield header attachment bracket is secured to a front portion ofthe inner roof panel. Right and left roof hold down clamp assemblies andright and left roof latch reinforcement plates are secured to right andleft sides of the inner panel of the roof. Right and left hold downbracket assemblies each comprise an upper plate, a bracket and a lowerplate that are secured together and to the B pillar of the vehicle byfasteners.

[0010] According to another aspect of the removable roof of the presentinvention, the removable roof may be formed with a side surface fromwhich side window openings may be cut out after molding. The inner panelof the roof may also be formed with cavities below and forward of theside window openings in which roof hold down clamp assemblies may besecured.

[0011] According to another aspect of the invention, a pivotal shaft isrotatably retained in each of the mounting brackets wherein a cam issecured on one end to each of the pivotal shafts that are received byeach of the hold down bracket assemblies. A cam follower may be attachedto each of the B pillar brackets for receiving the cam of each of thepivotal shafts and providing an engagement point for the cams to pullthe clamp assemblies into engagement with the hold down bracketassemblies. B pillar brackets are preferably assembled to reinforcementplates and fastener retention plates that are assembled together withfasteners that extend through fastener receptacle holes. The B pillarbracket preferably includes a horizontally extending flange, alongitudinally extending flange, and a transversely extending flangethat are mounted to a horizontal edge, and longitudinal surface of the Bpillar. Elongated slots preferably provided in the B pillar bracketspermit adjustment of the location of the B pillar bracket fore and aftand transversely and longitudinally to compensate for variations invehicle roof locating positions.

[0012] These and other aspects, objects and advantages of the presentinvention will be better understood by one of ordinary skill in the artupon review of the attached drawings and following detailed descriptionof the drawings and of the best mode of practicing the invention.

BRIEF DESCRIPTION OF DRAWINGS

[0013]FIG. 1 is a fragmentary side elevation view of a vehicle having aremovable roof made according to the present invention.

[0014]FIG. 2 is an exploded perspective view of a removable roof for avehicle;

[0015]FIG. 3 is an exploded perspective view of a hold down bracketassembly for a removable vehicle roof;

[0016]FIG. 4 is a cross-sectional view taken along the line 4-4 in FIG.2;

[0017]FIG. 5 is a flow chart illustrating the general steps in making aremovable roof for a vehicle;

[0018]FIG. 6 is a flow chart showing the steps required to mold an innerroof panel and assembling parts to the panel;

[0019]FIG. 7 is a flow chart for molding an outer roof panel;

[0020]FIG. 8 is a flow chart showing the process steps for assembling aninner roof and outer roof together as a sub-assembly;

[0021]FIG. 9 is a flow chart showing the process steps for painting aroof assembly;

[0022]FIG. 10 is a flow chart showing the process steps for assemblinghardware to the roof assembly;

[0023]FIG. 11 is a flow chart showing the process steps for installingside window glass and trim rings to a roof assembly; and

[0024]FIG. 12 is a flow chart showing the process steps for finalassembly of head liner, weather strips, wiring harness and other partsto a removable roof assembly.

BEST MODE FOR CARRYING OUT THE INVENTION

[0025] Referring now to FIGS. 1 and 2, a removable roof assembly 10 isshown that includes a molded outer roof panel 12 and a molded inner roofpanel 14 that are secured together. A head liner 16 is preferablyclipped, fastened, or bonded to the inner roof panel 14 on the oppositeside from the outer roof panel 12. A package tray or tonneau cover 18forms part of the convertible vehicle 20 to which the roof assembly 10is adapted to be secured. Vehicle 20 includes a door 22 that providesingress and egress to the front seat (not shown) of the vehicle 20. Itshould be understood that the present invention may be used with eithertwo-door or four-door vehicles.

[0026] The following description and the drawings illustrate thecomponent parts for the left side but does not in every instancedescribe or illustrate the corresponding right side parts for clarityand brevity. It should be understood that the right side includes mirrorimage parts corresponding to the left side parts described. Whenreference is made to a side part it should be understood that both rightand left sides are generally provided in the completed assembly.

[0027] Referring to FIG. 1, vehicle 20 including the roof assembly 10 isshown to illustrate the environment of the roof assembly of the presentinvention. The door 22 of the vehicle 20 is connected by a hinge to theA pillar 24 of the vehicle 20 rearward of the windshield 26. Thewindshield 26 includes a header 28 to which the roof assembly 10 isjoined as will be more particularly described below. The vehicle alsoincludes a B pillar 30 that terminates at the belt line 32 of thevehicle. As shown in FIG. 3, the B pillar 30 on its upper end includes ahorizontal edge 34 and a longitudinal surface 36.

[0028] Referring now to FIG. 2, a hold down clamp assembly 40 isprovided on the roof assembly 10 and is adapted to be secured to thehold down bracket assembly 42 that is mounted on the horizontal edge 34and longitudinal surface 36 of the B pillar 30. The hold down clampassembly 40 is secured to the inner roof panel by a hold down clampmounting plate 44. Hold down clamp assembly 40 includes a pivotal shaft46 and a lever 48. A cam 50 is provided on the distal end of the pivotalshaft 46 and is adapted to be rotated by moving the lever 48 whereby thehold down clamp assembly may be secured or released from the hold downbracket assembly 42.

[0029] As shown in FIGS. 2 and 3, the hold down bracket assembly 42includes a bracket 52 that is secured to the B pillar 30. Areinforcement plate 54 is secured to and reinforces the bracket 52. Afastener retention plate 56 is provided on the opposite side of thebracket plate 52 from the reinforcement plate 54. A cam track cylinder58 is secured by fasteners 60 to the bracket 52. Cam track cylinder 58includes a track in which the cam 50 is received that pulls the holddown clamp assembly 40 to the hold down bracket assembly 42 as the lever48 is rotated.

[0030] A transverse slot 62 is provided in the reinforcement plate 54. Atransverse flange 64 is provided on the bracket 52. Longitudinal slot 66is formed in horizontal flange 68. Bolts 70 are provided that extendthrough the transverse slot 62 and longitudinal slot 66 that arereceived by weld nuts 72 which are secured to the fastener retentionplate 56. Weld nuts 72 are aligned with hole 76 through which the bolt70 will pass. A pilot hole 77 is provided in the hold down bracketassembly 42 for passage of the cam 50 and pivotal shaft 46 that extendsthrough the reinforcement plate 54, B-pillar 34 and fastener retentionplate 56.

[0031] Referring now to FIGS. 2 and 4, a roll bar 78 is integrallyformed as part of the inner roof panel 14. The rollbar 78 includes legs80 that are interconnected by a bridge section 82. The construction ofthe rollbar 78 may include additional or special reinforcement fibersand is configured to provide crush strength sufficient to satisfyproposed or actual motor vehicle safety standards.

[0032] Referring now to FIG. 1, the windshield header 28 is engaged by afront portion of the roof 86.

[0033] Referring now to FIG. 2, rear window 88 is provided in the roofassembly 10. The rear window 88 may include an electrical defrostmechanism (not shown) for which a defrost wiring harness 90 is shown.The rear window 88 is secured over an opening in the roof assembly 10that extends through the inner and outer roof panels 14 and 12 and thehead liner 16 that are sized to correspond to the dimensions of the rearwindow 88. A rear window molding 92 is shown for securing the rearwindow 88 to the roof assembly 10 and sealing about the rear window 88.

[0034] A side window opening 94 is provided in the outer roof panel 12,inner roof panel 14, and head liner 16. A side window 96 is assembledover the side window opening 94 by an inner support ring 98 and an outermounting and trim ring 100.

[0035] A cavity 102 is preferably formed forward of the side window 96and adjacent the belt line 32 of the vehicle. The hold down clampassembly 40 is preferably received in the cavity 102 to minimize theextent to which the hold down clamp assembly 40 protrudes into thepassenger compartment of the vehicle 20.

[0036] With continuing reference to FIG. 2, additional parts of the roofassembly 10 that are located in the front portion 86 and engage theheader 28 will be described in greater detail. The front roof dripmolding 106, front roof seal plate 108, front roof inner plate 110,front roof connector 112, and front roof trim molding 114 are allsecured to the front portion of the roof 86. The seal plate 108 ispreferably bonded to the inner roof panel prior to assembly to the outerroof panel 12. The seal plate 108 preferably includes tapped holes orother mechanisms for securing other components of the roof in the frontportion of the roof 86.

[0037] Both sides of the roof assembly 10 are provided with a side roofdrip molding 118, a side roof rail weather strip 120 and a side roofinner tapping plate 122. The side roof inner tapping plate 122 ispreferably bonded to the inner roof panel 14 prior to assembling theinner roof panel 14 to the outer roof panel 12. The side roof innertapping plate 122 provides rigidity and a durable member to which thedrip molding and weather strip 118 and 120, respectively, are secured.

[0038] A hold down bracket cover 126 is provided to cover the hold downbracket assembly 42. A wiring harness 128 is provided to allow for thehold down clamp assembly 40 to be monitored by means of sensors (notshown). Electrical connectors 130 are shown for connecting sensors tothe hold down clamp assembly 40 or hold down bracket assembly 42 toprovide a convenient system for monitoring the position of the hold downclamp assembly 40. A side molding retainer 132 is secured to the outsideof the outer roof panel 12 as is a center molding retainer 134. Rearseal 136 and side moldings 138 and center molding 140 are secured to thelower rear edge 142 of the roof assembly 10.

[0039] The process for molding and assembling the roof assembly 10 isdescribed with reference to the attached process flow charts. FIG. 5presents an overview of the hard top assembly process. Each step of theoverview flow chart refers to subsequent figures that illustrate theprocess in greater detail.

[0040] Referring to FIG. 5, general process includes steps of moldingthe roof inner panel at 150. This general overview also shows theprocess element of molding the roof outer panel and performing subassembly at 152. The roof inner panel 14 and roof outer panel 12 subassemblies are assembled at 154. After the roof inner 14 and outerpanels 12 are assembled together at 154 the roof assembly 10 is paintedat 156. After painting, the roof assembly 10 hardware is installed at158. The roof assembly glass installation process steps are representedby reference number 160. The roof assembly 10 undergoes final assemblysteps at 162.

[0041] Referring now to FIG. 6, molding of the roof inner panel 14 isdepicted. A sheet molding compound (hereinafter “SMC”) charge is cut andweighed according to a predetermined pattern at 164. The SMC chargepattern is loaded into the roof inner panel mold at 166. The SMC ismolded by compression molding to form the general structure of the roofinner panel to near net size and shape at 168. The deflashing step 170includes the step of deflashing the edges of the roof inner panel 14 andcutting the window openings. The roof inner panel 14 is transferred to aroof assembly bond fixture represented by reference number 172.

[0042] Referring now to FIG. 7, the roof outer panel mold and subassembly process is shown to begin with cutting and weighing the SMCcharge pattern at 180. The SMC charge pattern is loaded into the roofouter panel mold at 182. The SMC charge is compression molded to formthe roof outer panel 12 at 184. After forming, the roof outer panel 12is coated in the mold at 186. The roof outer panel 12 is deflashed at188 wherein the perimeter of the roof outer panel is deflashed and theside window openings are cut. The roof outer panel 12 is thentransferred from the deflash fixture to the roof assembly bond fixtureas represented by reference number 190.

[0043] Referring now to FIG. 8, the roof inner panel 14 and roof outerpanel 12 sub assembly process is described in greater detail. The roofouter panel is first clamped into the roof assembly bond fixture at 192.An adhesive is applied to bond flange surfaces and side window trim ringsurfaces at 194. The roof inner panel is then fixtured and clamped inthe roof assembly bond fixture at 196. The side window trim rings 100are assembled on the roof outer panel 12 at 198. The inner and outerroof sub assembly is then transferred from the roof assembly bondfixture to the paint line at 200.

[0044] Referring now to FIG. 9, the roof assembly painting process isshown to include fixturing the roof inner and outer assembly 10 on apaint rack at 202. The inner and outer roof assembly 10 is then paintedin the paint primer station at 204. Roof assembly 10 is then painted atthe paint station 206 and then is transferred to a storage rack 208.

[0045] Referring now to FIG. 10, hardware attachment to the roofassembly 10 is shown in detail. The A and B pillar roof mountingbrackets 40 and 112 are loaded into the mounting bracket assemblyfixture at 210. The roof assembly is fixtured and clamped in the bracketassembly fixture at 212. Hardware and trim parts are attached to theroof assembly at 214. The A and B pillar roof mounting bracket fixturedetails are located in body position at 216. The A and B pillar roofbrackets 40 and 112 are then assembled to the roof assembly at 218. Theroof assembly with hardware attached is then transferred to the windowbond fixture at 220.

[0046] Referring now to FIG. 11, installation of glass in the roofassembly is described in more detail. The roof assembly is clamped intothe window bond fixture at 222. Glass 96 is assembled to the adhesive onthe side window trim rings 100 at 224. The trim rings 98 and 100 arethen assembled to the window trim rings at 226. The roof assembly 10with glass installed is then transferred to the roof head liner andweatherstrip assembly fixture at 228.

[0047] Referring now to FIG. 12, the final assembly steps are describedin detail. The roof assembly is clamped in head liner and weather stripassembly fixture at 230. The head liner wiring harness 128 is clipped tothe roof assembly at 232 and the head liner 16 is attached to the roofassembly at 234. Weather stripping is attached to the roof assembly at236. The A and B pillar roof bracket mounting covers 126 are attached tothe roof assembly at 238 and the package tray 18 is attached to the roofassembly at 240 prior to being transferred to a storage rack at 242.

[0048] While embodiments of the invention have been illustrated anddescribed, it is not intended that these embodiments illustrate anddescribe all possible forms of the invention. Rather, the words used inthe specification are words of description rather than limitation, andit is understood that various changes may be made without departing fromthe spirit and scope of the invention.

What is claimed is:
 1. A method of making a removable roof for a vehiclecomprising: heating a first mold for forming an outer panel of the roof;placing a first sheet of thermoset plastic resin having fiberreinforcement material distributed in the resin in the first mold;forming the sheet in the first mold to net size and shape of a roofouter panel; trimming the roof outer panel; heating a second mold forforming an inner panel of the roof; placing a second sheet of thermosetplastic resin having fiber reinforcement material distributed in theresin in the second mold; forming the sheet in the second mold to netsize and shape of a roof inner panel; trimming the roof inner panel;assembling mounting brackets and locking assemblies to the roof innerpanel; bonding the roof outer panel and roof inner panels together toform the removable roof for a vehicle.
 2. The method of claim 1 whereinthe second mold includes a cavity for forming an integral roll bar andthe step of forming the roof inner panel includes forming a roll bar inthe roof inner panel.
 3. The method of claim 1 wherein the fiberreinforcement material in the first and second sheets of thermoset resinare glass fibers.
 4. The method of claim 1 wherein the fiberreinforcement material in the first and second sheets of thermoset resinare selected from the group consisting essentially of: carbon fibers,glass fibers, steel fibers, polyacrylonitrile fibers, and combinationsthereof.
 5. In combination, a hold down clamp assembly and hold downbracket assembly for a removable roof for a vehicle having a B pillar,comprising: a mounting bracket for fastening the hold down clampassembly to the roof; a pivotal shaft rotatably retained in the mountingbracket; a lever secured to the pivotal shaft for pivoting the shaft inan arcuate path; a B pillar bracket for fastening the hold down bracketassembly to one side of one or more flanges of the B pillar of avehicle; a reinforcement plate secured to another side of the one ormore flanges of the B pillar of the vehicle; and a fastener retentionplate secured to the B pillar bracket on the opposite side thereof fromthe reinforcement plate.
 6. The combination of claim 5 furthercomprising a pilot hole and a plurality of fastener receptacle holesformed in the B pillar bracket, the reinforcement plate and fastenerretention plate are aligned when assembled together with fastenersextending through the fastener receptacle holes and the pivotal shafthaving an end extending into the pilot hole.
 7. The combination of claim5 wherein the B pillar bracket has a horizontally extending flange, alongitudinally extending flange and a transversely extending flange thatare mounted to a horizontal edge of the B pillar, a longitudinal surfaceof the B pillar and a transverse surface of the B pillar, respectively.8. The combination of claim 5 wherein elongated slots are provided inthe B pillar bracket parts to permit adjustment of the location of the Bpillar bracket fore and aft and transversely.
 9. A removable roof for avehicle having a windshield having a header and a B pillar having anupper end terminating at a belt line of the vehicle, the removable roofcomprising: a fiber reinforced thermoset resin outer panel; a fiberreinforced thermoset resin inner panel including an integrally formedroll bar; right and left roof hold down clamp assemblies and right andleft roof latch reinforcement plates secured to right and left sides ofthe inner panel; right and left roof hold down bracket assemblies eachcomprising an upper plate, a bracket and a lower plate that are securedtogether and to the B pillar of the vehicle by fasteners, wherein thehold down bracket assemblies are each mounted on the B pillar to receiveone of the roof hold down clamp assemblies; and a windshield headerattachment bracket secured to a front portion of the inner roof panel.10. The removable roof of claim 9 wherein the inner and outer panelsdefine a side window opening, the removable roof further including awindow mounted in the side window opening, the right and left roof holddown clamp assemblies being secured partially within cavities formed inthe inner panel below and forward of the side window opening.
 11. Thecombination of claim 9 wherein the hold down bracket has a horizontallyextending flange, a longitudinally extending flange and a transverselyextending flange that are mounted to a horizontal edge of the B pillar,a longitudinal surface of the B pillar and a transverse surface of the Bpillar, respectively.
 12. The combination of claim 11 wherein elongatedslots are provided in the hold down bracket to permit adjustment of thelocation of the hold down bracket on the B pillar fore, aft andtransversely.